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Home >> Chevrolet >> 2006 >> HHR L4-2.2L >> Repair and Diagnosis >> Powertrain Management >> Fuel Delivery and Air Induction >> Fuel Rail >> Service and Repair
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Fuel Rail: Service and Repair



FUEL RAIL ASSEMBLY REPLACEMENT

REMOVAL PROCEDURE




1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure.
2. Remove the air cleaner assembly.
3. Disconnect the fuel feed line quick connect fitting from the fuel rail.




4. Disconnect the fuel injector harness electrical connector (3).




5. Remove the fuel injector harness electrical connector clip (4) from the intake manifold.




6. Remove the fuel rail studs.
7. Pull the fuel rail back and upward in order to release the fuel injectors from the cylinder head ports.

IMPORTANT: Use care when removing the fuel rail assembly in order to prevent damage to the fuel injectors electrical connector terminals and spray tips.

8. Remove the fuel rail.
9. Remove the fuel injectors, if necessary.

INSTALLATION PROCEDURE

IMPORTANT: Install new lower O-rings when reusing fuel injectors. Lubricate the injector tip O-rings prior to installing the injectors into the intake manifold.




1. Install the fuel injectors, if necessary.
2. With the fuel injectors positioned downward, lower the fuel injectors into the cylinder head ports.
3. Carefully push the fuel injectors into the cylinder head ports.
4. Install the fuel rail bolts.

NOTE: Refer to Fastener Notice.

Tighten the bolts to 10 N.m (89 lb in).




5. Connect the fuel injector harness electrical connector (3).




6. Install the fuel injector harness electrical connector clip (4) to the intake manifold.




7. Connect the fuel feed line quick connect fitting to the fuel rail.
8. Install the air cleaner assembly.
9. Connect the negative battery cable.
10. Inspect for fuel leaks using the following procedure:
1. Turn ON the ignition, with the engine OFF for 2 seconds.
2. Turn OFF the ignition for 10 seconds.
3. Turn ON the ignition.
4. Inspect for fuel leaks.
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